Adjustable Contour Mattress System

ABSTRACT

An adjustable contour mattress is provided with a multiplicity of zones each having a mattress height independently adjustable by a respective electro-mechanical actuator. The actuators are disposed within the mattress between a lower panel member and an upper mattress layer. A control unit is connected to the actuators for operating them to alternately raise and lower respective zones of the upper mattress layer. A remote control is operatively connected to the control unit and includes command input elements enabling an individual user to selectively operate the actuators independently of other ones of the actuators, whereby the user can adjust heights of the zones independently of one another.

BACKGROUND OF THE INVENTION

This invention relates to a mattress having an adjustable contour.

Standard off-the-shelf mattresses and pillows are not designed to satisfy individual needs for contour and hardness and accordingly fail to provide adequate support to the spine and neck of the user. In particular, many elderly people have trouble finding a mattress and pillow on the market which would fit 100% their needs for relief from shoulder pain, neck pain, back pain resulting from improper support to their body because of the less-than-optimum contour and hardness of their mattresses.

The prior art includes air-bag-type mattresses for pressure sore relief and with low contact pressure for comfort. There are also adjustable bed support frames (like those commonly used in hospitals) available on the market.

However, there is no tailor made mattress and pillow available in the market place for adapting a mattress to fit individual needs in the manner of tailor made shoes and clothing.

Consequently, there is a need for a mass production mattress and pillow that are cost affordable by the public but also allow the user to adjust the contour by the user as they wish.

SUMMARY OF THE INVENTION

The present invention aims to provide an improved mattress. More particularly, the present invention aims to provide an improved mattress that enables custom modification of the mattress contour in accordance with the preferences and needs of the individual user. The term “contour” is used herein to mean a profile of an upper surface of a mattress. The contour is variable in accordance with the operation of multiple mattress height actuators and is user adjustable. Mattress contour may be adjustably variable in just one dimension, along the length of the mattress, or in two dimensions, including both length and width.

The present invention aims to provide a manually adjustable electro-mechanical mattress that allows the user to adjust and change the contour of the mattress and pillow to get the best support he or she wishes.

The present invention particularly contemplates a mattress system provided with multiple zones along its full length or partial length (see FIG. 1) starting from the pillow end.

An adjustable contour mattress system in accordance with the present invention comprises a support frame, a mattress, a multiplicity of actuators, a control unit and a remote control. The support frame has at least one lower panel member along a bottom periphery of the frame, while the mattress has an at least partially resilient upper layer and is provided with a multiplicity of height-adjustable zones. The actuators equal in number to the mattress zones and are disposed within the mattress between the lower panel member and the upper layer. The control unit is operatively connected to the actuators for operating same to alternately raise and lower respective zones of the upper layer. The remote control is operatively connected to the control unit and includes command input elements enabling an individual user to selectively operate the actuators independently of other ones of the actuators, whereby the user can adjust heights of the zones independently of one another. The control of zone height may be effectuated in real time, that is, while the user is on the mattress. Alternatively, or additionally, user adjustment of mattress zone height may be implemented via electronic storage of user-adjusted mattress contours and subsequent operation of mattress height actuators pursuant to the stored mattress contour. Typically, mattress contour adjustment is effectuated while the user is lying on the mattress. Contour adjustments may be stored as “canned” contours per user direction.

The control unit and the remote control may be incorporated into the same housing, which may be a handheld device or a tabletop console. The remote control and the control unit may be operatively connected to the actuators via electrical wires or wireless transmission links. Where a handheld remote and a control unit are provided in separate casings, the handheld may be operatively connected to the control unit via a hard-wired or a wireless transmission path.

It is contemplated that the actuators include mechanical linkages, preferably electrically powered. Each of the actuators may include a motor with a speed reduction gear box operatively connected to a screw shaft for alternately rotating the shaft in opposite directions. The screw shaft is linked to the driving gear box and a screw nut at each end.

Alternatively, each of the actuators may include a scissor linkage, at least one camming member, a screw jack actuator, or a rack and pinion assembly.

In another alternative embodiment the actuators are linear actuator, for instance, hydraulic cylinders, pneumatic cylinders, or motorized ball screw linear actuators.

A method for adjusting a mattress comprises, in accordance with the present invention, providing a mattress having a multiplicity of height-adjustable zones and a multiplicity of actuators equal in number to the zones and disposed within the mattress, operating the actuators to elevate the zones to respective heights, and operating a remote control to selectively adjust an individual one of actuators to adjust the height of the respective mattress zone.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is partially a schematic isometric view, partially broken away, and partially a block diagram of a mattress system in accordance with the present invention.

FIG. 2 is a schematic partial side elevational view of an actuator assembly in a height adjustment zone of the mattress system of FIG. 1, said the actuator assembly in a collapsed or low-elevation configuration.

FIG. 3 is a schematic partial side elevational view similar to FIG. 2, showing the actuator in a raised of high-elevation configuration.

FIG. 4 is schematic a longitudinal cross-sectional view of the mattress of FIG. 1, showing a contoured mattress upper layer.

FIGS. 5A-5D are schematic partial side elevational views of alternative mattress-height actuators in accordance with the present invention.

FIG. 6 is a schematic isometric view, partially broken away, of a mattress in another adjustable mattress-height system in accordance with the present invention.

FIG. 7 is a schematic isometric view of a linear mattress-height actuator utilizable in the mattress of FIG. 6.

FIG. 8 is a block diagram of components of a control unit and a remote control shown in FIG. 1.

FIG. 9 is a block diagram of components of a central processing unit shown in FIG. 8.

DETAILED DESCRIPTION

As depicted in FIG. 1, an adjustable contour mattress system comprises a support frame 10, a mattress 12, a multiplicity of actuators 14, a control unit 16 and a remote control 18. Support frame 10 has at least one lower panel member 20 along a bottom periphery of the frame. Mattress 12 has an at least partially resilient upper layer 22 made of padded or foam material and is provided with a multiplicity of height-adjustable zones 24. Actuators 14 are equal in number to mattress zones 24 and are disposed within mattress 12 between lower panel member 20 and upper layer 22. Control unit 16 is operatively connected to actuators 14 for operating the actuators independently of one another to alternately raise and lower respective zones 24 of upper layer 22. Remote control 18 is operatively connected to control unit 16 and includes command input elements 26 (e.g., keypads, FIG. 4) enabling an individual user USR (FIG. 4) to selectively or separately operate actuators 14 so that the user can adjust the heights of zones 24 independently of one another. Typically, mattress contour adjustment is effectuated while the user is lying on the mattress. Contour adjustments may be stored as “canned” contours per user direction. Accordingly, a direct adjustment of mattress contour in response to user operation of remote control 18 may occur only during a calibration phase. Subsequent changes to mattress contour may then occur only in response to user selection of a particular stored mattress contour. Of course, once the user selects a stored mattress contour, regardless of whether that contour is a preprogrammed contour pursuant to factory specifications or includes user-selected mattress-height adjustments, the user may operate remote control 18 to adjust or “fine tune” the various mattress zone heights per preferences of the moment.

Control unit 16 and remote control 18 may be incorporated into the same housing 28, which may be a handheld device casing or a tabletop console cabinet. Alternatively, remote 18 and control unit 16 may be provided in separate casings, the handheld may be operatively connected to the control unit via a hard-wired or a wireless transmission path 34 (FIG. 4). Remote control 18 and control unit 16 may be operatively connected to actuators 14 via electrical wires 30 or wireless transmission links 32 (FIG. 2).

As shown in FIGS. 2 and 3, actuators 14 include pairs of mechanical linkages 36 each connected via a respective screw nut 38 to a drive shaft 40. Each actuator 14 further includes an electrical motor 42 with an incorporated speed reduction gearbox operatively connected to drive or screw shaft 40 for alternately rotating the shaft in opposite directions. In response to instructions from the user USR via remote control 18, control unit 16 activates each motor 42, as required, to rotate the respective screw shaft 40 in one direction or the other to raise or lower the respective zone 24 of mattress upper layer 22.

Linkages 36 elevate the respective height-adjustable zone 24 when the screw nuts 38 are moved inward (towards each other, see FIG. 3) or lower the adjustable zone base when the screw nuts are moved outwards (away from each other). Linkages 36 are pivotably connected at their lower ends to lower frame panel 20 and at their upper ends to respective substantially rigid upper panel sections 43. Each upper panel section 43 holds a respective foam mattress under section 45 atop which mattress upper layer 22 is disposed.

FIG. 4 shows upper layer 22 of mattress 12 contoured pursuant to the preferences and needs of user USR.

As illustrated in FIG. 5A, each actuator 14 may include a scissor linkage 44. Each scissor linkage 44 includes a pair of arms 46 pivotably connected to one another at a pin 48, respectively connected to lower panel 20 and an upper panel section 50 at pivot pins 52, and slidably connected to upper panel section 50 and lower panel 20 at sliders 54. A linear force 56 applied to linkage 44 results in an upward translation of upper panel section 50 and an overlying mattress zone 24, as indicated by an arrow 58.

As shown in FIG. 5B, each actuator 14 may alternatively include a pair of camming members 60, 62 mounted on respective sheaves or gears 64, 66 in turn entrained to an endless belt or chain 68 that is movable in alternate directions 70 by a motor 72.

As depicted in FIG. 5C, each mattress height actuator 14 may alternatively take the form of a screw jack actuator including a screw 74 fixed at an upper end to an upper panel section 76. Screw 74 threadingly engages a drive gear 78 that is rotatably held at a fixed vertical location by a support panel 80 and that drivingly meshes with a pinion 82 of an electrical motor 84. Upper panel section 76 carries a pair of guide pins that slidably traverse openings (not shown) in support panel 80. Other operative configurations of a screw jack actuator will occur to those skilled in the art.

FIG. 5D shows a rack and pinion assembly 86 that may serve as a mattress height actuator 14. Rack and pinion assembly 86 includes two racks 88, two pinions 90, and a guide panel 92.

In FIG. 1, height adjustment zones 24 are elongate areas each extending across the main portion of the mattress width. FIG. 6 shows a mattress 94 with a grid of height adjustment zones 96 in a central region, as well as elongate zones 98 and 100 at a head region and a foot region (not separately labeled), respectively. In the grid area, mattress 94 incorporates linear actuators 102 (see also FIG. 7) in the form of hydraulic cylinders, pneumatic cylinders, or motorized ball screw linear actuators. Each linear actuator 102 includes a body 104 and a plunger 106. Body 104 is fastened to a lower (substantially rigid) panel 108 of mattress 94, while an upper end of plunger 106 is fixed to a substantially rigid upper panel section 110 that supports a portion of a soft mattress under layer section 112.

Remote control 18 and/or a console (not separately shown) of control unit 16 may be provided with a display (not shown) that provides menu selections or options, instructions, messages and recommendations to the user USR. Control unit 16, via a keypad or touch screen interface 114 of the remote control 18 (see FIG. 6), may provide the user USR with the option of selecting from a plurality of “canned” or preprogrammed sets of mattress zone heights. Further selections may be made from among user-generated or user-modified sets of mattress zone heights. Upon selection of such a preexisting mattress zone height array, the user has the ability to adjust the height of each zone 24, 96, 98, 100 to suit the user's contemporaneous requirements and preferences. Such modifications may be stored in control unit 16 as separate mattress contours for selection and deployment at a later time.

Control unit 16 typically stores mattress contours or sets of zone heights for the following basic sleep postures: flat on the stomach, flat on the back, on the left side, on the right side. Modifications of these may include respective tilts for the head and inclinations of the thigh. A modification of the back-flat pose is a bend at the waist that approximates a sitting posture to a greater or lesser extent.

The widths “W” of the zones 24, 96, 98, 100 may vary and typically range from 1 inch to 24 inches. The length “L” of the “grid” zones 96 (FIG. 6) may have a value between 3 inches and 12 inches.

The vertical displacement ranges of each zone 24, 96, 98, 100 may vary and range from 1 inch to 10 inches. Control unit 16 may be programmed to limit height differences between adjacent zones where large differences in height would be impractical or impose undue stress on the mattress upper layer 22 and the user USR.

Height adjustment of mattress zones underneath a pillow 116, 118 (FIGS. 1, 4, 6) changes the contour of the pillow as well and providing head and neck support as the user USR wishes.

Any desired pillow and mattress contour could be achieved by the combined position of the individual zones 24, 96, 98, 100 (see FIG. 4).

A mattress 12 as described herein may incorporate stuffed or foam sections 120 that are not adjustable in height.

As depicted in FIG. 8, control unit 16 may comprise a central processing unit (CPU) 124 that accesses a memory 126 containing program instructions for directing and enabling communications with a user via remote control 18 and for operating various height-adjusting actuators 128. A first data store 130 contains preprogrammed sets of mattress zone heights constituting a number of “canned” sleep postures. A second data store 132 contains sets of mattress zone heights that have been modified in accordance with input from a user. CPU 124 communicates with remote control 18 via a transmitter 134 and a receiver 136 of control unit 16 and via a receiver 138 and a transmitter 140 of remote unit 18. Remote unit 18 further includes a CPU 142 operating under instructions from a resident program memory 143 to control a display 144 and field user instructions from a command input 146 in the form of a keypad. The functions of display 144 and keypad 146 may be combined in a touch screen.

Control unit 16 and remote control 18 may incorporate or comprise one or more microprocessors. Thus, CPU 124 may be implemented by a microprocessor. In that case, CPU 124 comprises generic digital processing circuits modified by programming from instruction memory 126 to execute the height adjustment functions described herein. Alternatively, control unit 16 and/or remote 18 may comprise integrated circuits with component parts hard-wired for processing user selections of mattress zone heights, storing encoded mattress contour data incorporating user height adjustments (e.g., in data store 132), and issuing signals to actuators 128 for controlling mattress contour pursuant to user input. A combination of hard-wired and generic program-modified circuits is yet another alternative. Such alternative control unit embodiments are well within the ken of those skilled in the art.

As depicted in FIG. 9, CPU 124 comprises functional modules including a contour selection module 148, an actuator activation module 150, and a height adjustment module 152. Contour selection module 148 is connected at inputs to data stores 130 and 132 and memory 126 and at outputs to actuator activation module 150 and height adjustment module 152. Actuator activation module 150 is in turn connected to instruction or program memory 126 and at outputs to actuators 128 (FIG. 8). Height adjustment module 152 is connected to memory 126 and to remote control 18 via transmitter 134 and a receiver 136.

In response to a user's contour selection (e.g., back, right side, etc.), received from remote control 18 via height adjustment module 152, contour selection module 128 extracts the appropriate contour data from store 130. Contour selection module 128 checks whether the user previously modified the contour data for the selected posture, by accessing data store 132. Contour selection module 128 forwards the contour information, with adjusted height data if available, to actuator activation module 150 for operation of actuators 128. Actuator activation module 150 periodically inquires with height adjustment module 152 as to whether any mattress zone height is to be modified from the stored value. Height adjustment module 152 communicates with remote control 18 to field any requests from the user for adjustment of the current mattress profile, as well as requests to store adjustments. In the event of the latter type of request, height adjustment module 152 accesses store 132 to change the appropriate height or contour information stored therein. CPU 142 of remote control 18 includes modular components for energizing display 144 and collecting requests input by the user via keypad 146.

As indicated above, contour selection module 148, actuator activation module 150, and height adjustment module 152 may be implemented by generic digital processing circuits modified by programming from instruction memory 126 to execute the height adjustment functions described herein. Or contour selection module 148, actuator activation module 150, and height adjustment module 152 may comprise hard-wired integrated circuits or a combination of hard-wired and generic program-modified circuits.

Although the invention has been described in terms of particular embodiments and applications, one of ordinary skill in the art, in light of this teaching, can generate additional embodiments and modifications without departing from the spirit of or exceeding the scope of the claimed invention. For example, the control unit and the remote controller may be pre-programmed with different zone height arrays each corresponding to a respective sleep posture or position of an average user. During an initial use of the mattress system, a user selects a zone height array of prospective interest and lies down on the bed (not necessarily in that order). The user then selectively adjusts the zone heights in accordance with the user's preferences. Upon discovering a comfortable configuration, the user may instruct the control unit via the remote control (or a separate console or keypad) to store the configuration for future use.

Adjustment of mattress zone heights may be accomplished by other types of actuators, different from the electromechanical actuators discussed hereinabove. For instance, a mattress may incorporate multiple pressurized compartments operatively connected via respective valves to a source of compressed air, as described in U.S. Pat. No. 7,107,642 the disclosure of which is hereby incorporated by reference. Pursuant to the present invention, the individual user interacts with a control unit to adjust the heights (or pressures) of individual mattress compartments to thereby construct a customized mattress contour, which is stored in encoded format in a memory. During subsequent use of the mattress adjustment apparatus, the control unit operates the valves to increase or decrease the pressures in the individual compartments pursuant to the stored customized mattress contour data.

Accordingly, it is to be understood that the drawings and descriptions herein are proffered by way of example to facilitate comprehension of the invention and should not be construed to limit the scope thereof. 

1. An adjustable contour mattress system comprising: a support frame having at least one lower panel member along a bottom periphery of said frame; a mattress having an at least partially resilient upper layer and provided with a multiplicity of independent height-adjustable zones; a multiplicity of actuators equal in number to said zones and disposed within said mattress between said lower panel member and said upper layer; a control unit operatively connected to said actuators for operating same to alternately raise and lower respective zones of said upper layer; and a remote control operatively connected to said control unit, said remote control having command input elements enabling an individual user to select heights of said zones independently of one another.
 2. The mattress system defined in claim 1 wherein said actuators include mechanical linkages.
 3. The mattress system defined in claim 2 wherein said actuators are electrically powered.
 4. The mattress system defined in claim 1 wherein each of said actuators includes a motor with a speed reduction gear box operatively connected to a screw shaft for alternately rotating said shaft in opposite directions.
 5. The mattress system defined in claim 4 wherein said screw shaft is linked to the driving gear box and a screw nut at each end.
 6. The mattress system defined in claim 1 wherein each of said actuators includes a scissor linkage
 7. The mattress system defined in claim 1 wherein each of said actuators includes at least one camming member.
 8. The mattress system defined in claim 1 wherein each of said actuators includes a screw jack actuator.
 9. The mattress system defined in claim 1 wherein each of said actuators includes a rack and pinion assembly.
 10. The mattress system defined in claim 1 wherein each of said actuators includes a linear actuator.
 11. The mattress system defined in claim 1 wherein said linear actuator is taken from the group consisting of a hydraulic cylinder, a pneumatic cylinder, and a motorized ball screw linear actuator.
 12. The mattress system defined in claim 1 wherein said remote control has command input elements enabling an individual user to select heights of said zones independently of one another.
 13. A method for adjusting a mattress, comprising: providing a mattress having a multiplicity of height-adjustable zones and a multiplicity of actuators equal in number to said zones and disposed in operative relationship with respect to said mattress to effectuate adjustment of mattress contour; operating said actuators to elevate said zones to respective heights; and operating a remote control to select the heights of individual ones of said zones, the operating of said actuators being in conformity with the heights of said individual ones of said zones as selected via the operating of said remote control.
 14. The method defined in claim 13 wherein the operating of said remote control includes generating height-adjustment signals and automatically modifying stored data encoding the heights of said individual ones of said zones.
 15. The method defined in claim 13 wherein the operating of said actuators includes operating a control unit to access a memory to extract mattress height data determined at least in part by the operating of said remote control. 